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Housing For Movement Sensor With Protective Cover For Components - Patent 7463019

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United States Patent: 7463019


































 
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	United States Patent 
	7,463,019



 Kaltenbach
,   et al.

 
December 9, 2008




Housing for movement sensor with protective cover for components



Abstract

The invention relates to a device for detecting the movement of a movable
     component, the device having an inner part 1 and the inner part 1 having
     a housing in which are mounted conductors 3 that carry electrical
     components 4 and a sensor element. One end of each conductor 3 protrudes
     from the inner part 1 forming plug contacts 6, and the inner part 1 is
     encapsulated by a plastic housing 2 in such a way that the plug contacts
     6 project into a plug receiver 5 in the plastic housing. The electrical
     components 4 and the sensor element are covered by covers and
     encapsulated by the plastic housing 2. The covers protect the components
     from the plastic in the encapsulation process.


 
Inventors: 
 Kaltenbach; Dirk (Wiesbaden, DE), Skarpil; Harry (Dortmund, DE) 
 Assignee:


Siemens Aktiengesellschaft
 (Munchen, 
DE)





Appl. No.:
                    
11/578,984
  
Filed:
                      
  March 18, 2005
  
PCT Filed:
  
    March 18, 2005

  
PCT No.:
  
    PCT/EP2005/051266

   
371(c)(1),(2),(4) Date:
   
     October 18, 2006
  
      
PCT Pub. No.: 
      
      
      WO2005/101027
 
      
     
PCT Pub. Date: 
                         
     
     October 27, 2005
     


Foreign Application Priority Data   
 

Apr 19, 2004
[DE]
10 2004 018 869



 



  
Current U.S. Class:
  324/173  ; 324/207.2
  
Current International Class: 
  G01P 3/487&nbsp(20060101); G01B 7/14&nbsp(20060101); G01R 33/06&nbsp(20060101); H01L 43/06&nbsp(20060101)
  
Field of Search: 
  
  












 324/207.13,207.15,207.2,207.21,251,160,173,174,178,180 338/32R,32H 29/602.1
  

References Cited  [Referenced By]
U.S. Patent Documents
 
 
 
4298769
November 1981
Richman

5585560
December 1996
Goossens

6025710
February 2000
Schneider et al.

6131270
October 2000
Van Den Berg

2002/0109264
August 2002
Lechner



 Foreign Patent Documents
 
 
 
38 27 937
Feb., 1990
DE

42 01 328
Jul., 1993
DE

43 23 084
Jan., 1995
DE

44 22 951
Jan., 1996
DE

197 44 673
Jun., 1999
DE

1 231 824
Aug., 2002
EP

2000088984
Mar., 2000
JP



   
 Other References 

German Office Action dated Jun. 25, 2007 issued in corresponding application No. 10 2004 018 869.6. cited by other. 

  Primary Examiner: Whittington; Kenneth J


  Attorney, Agent or Firm: Cohen Pontani Lieberman & Pavane LLP



Claims  

What is claimed is:

 1.  A device for detecting movement of a movable component, said device comprising: an inner part encapsulated by injection-molding or casting a housing with at least one
chamber and a plug socket;  at least one conductor disposed in said housing and bearing an electrical component and a sensor element, said electrical component and said sensor each being disposed in said at least one chamber, said at least one conductor
having an end protruding from said plug socket of said inner part to form a plug contact;  and a cap closing the at least one chamber and having an outer contour corresponding to an outer contour of said inner part surrounding said at least one chamber,
wherein said cap and the inner part are plastic and said cap is connected to said inner part by a film hinge.


 2.  The device of claim 1, wherein said cap is held in an installation position on said inner part by a latching connection.


 3.  The device of claim 1, wherein said at least one conductor is formed by a metal stamping and each of said electrical component and said sensor element is welded or soldered to said at least one conductor.


 4.  The device of claim 1, wherein said sensor element comprises a Hall element and is disposed at an end of said at least one conductor that is opposite from the end forming said plug contact.  Description
 

CROSS REFERENCE TO RELATED APPLICATIONS


This is a U.S.  national stage of application No. PCT/EP2005/051266, filed on 18 Mar.  2005.  Priority is claimed on the following application(s): Country: Germany, Application No.: 10 2004 018 869.6, Filed: 19 Apr.  2004.


BACKGROUND OF THE INVENTION


The invention relates to a device for detecting the movement of a movable component, the device having an inner part and the inner part possessing a housing in which conductors are disposed which bear electrical components and a sensor element
and which with their one ends protrude from the inner part to form plug contacts, the inner part being encapsulated by injection-molding or casting methods in such a way that the plug contacts project into a plug socket in the plastics housing.


In devices of this type, it is known that, in the injection-molding to encapsulate the inner part with the plastics housing, the electrical components and/or the sensor element are also directly encapsulated.  Both during production, as a result
of the injection pressure and the high temperatures of the injection-molding compound and the subsequent cooling thereof, and later during operation in the event of temperature fluctuations, the connections of the electrical components and/or of the
sensor element are subjected to mechanical load and can become detached.


In sensor elements which react to mechanical load with changes in their electrical properties, the result may be considerable losses in accuracy, or even failure of the device.


Moreover, the thermal and the compressive load can lead to defects in sensitive electrical components.


SUMMARY OF THE INVENTION


An object of the invention is therefore to provide a device of the type stated in the introduction which prevents damage to the electrical components and/or to the sensor element.


This object is achieved according to the invention by the fact that the electrical components and/or the sensor element are covered by covers and are encapsulated by the plastics housing by injection-molding or casting methods.


By virtue of this configuration, the electrical components and/or the sensor element are prevented from coming into contact with the encasing material of the plastics housing, so that the loads which are generated in the encasing operation, as a
result of the pressure applications which arise during the injection-molding or casting and concurrent or subsequent thermally-induced expansion processes of the encasing compound, are kept remote from the electrical components and/or the sensor element. Damage caused by loads of this type is thus at least largely prevented.


The manufacturability of the device is here particularly simple if the inner part has one or more chambers in which the electrical components and/or the sensor element are disposed, the chambers being closed off by the covers in the direction of
the exterior of the inner part and being encapsulated by the plastics housing by injection-molding or casting methods.


In simple configuration, the covers can here be caps which close off the chambers.


An undisturbed flowing of the plastic during the encapsulation of the inner part is achieved by virtue of the fact that the caps possess an outer contour which, in the installation position of the


cap, at least broadly corresponds to the outer contour of the inner part which surrounds the chamber.


For the securement of the caps in their installation position, the caps can be held in their installation position on the inner part by means of a latching connection.


A reduction in components and in the complexity of assembly is obtained if the cap and the inner part consist of a plastic and the cap, at one of its marginal regions, is connected to the inner part by means of a film hinge.


A simple and stable manufacture is obtained if the conductors are formed by a metal stamping (leadframe) and the electrical components, as well as the sensor element, are welded or soldered to the conductors.


The sensor element can be a Hall element, which is disposed at that end region of the conductors which is opposite to the plug contacts. 

BRIEF DESCRIPTION OF THE DRAWINGS


An illustrative embodiment of the invention is represented in the drawing and is described in greater detail below, wherein


FIG. 1 is a sectional view of a rotational-speed sensor according to an embodiment of the invention in section,


FIG. 2 is a side view of an inner part of the rotational-speed sensor according to FIG. 1, with open chambers, and


FIG. 3 is a perspective view of the inner part according to FIG. 2, with a covered chamber.


DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS


The rotational-speed sensor represented in the figures is used to detect the rotational speed of a magnetically coded wheel (not represented) by generation of corresponding pulses.  As shown in FIGS. 1-2, the rotational-speed sensor possesses a
plastics inner part 1, which, through encapsulation with a plastics injection-molding compound, is disposed in a plastics housing 2.  The inner part 1 has inside it conductors 3, which are configured as a metal stamping and on which electrical components
4 are disposed by welding.  These electrical components 4 are located in a chamber 12 configured in the inner part 1.


The one ends of the conductors 3 project into a plug socket 5 in the plastics housing 2 and form plug contacts 6.


At those ends of the conductors 3 which are opposite to the plug contacts 6 there is disposed, likewise by welding, a Hall element 7, which is likewise located in a chamber 13 of the inner part 1.


In a region close to the plug socket 5, the plastics housing 2 possesses a fastening flange 8, molded on in one piece, comprising an injection-molded metal bushing 10 having a fastening bore 9.


Large regions of the inner part are encapsulated with a plastic forming the housing 2, that region of the inner part 1 which is opposite to the plug socket 5 possessing an approximately pillar-like outer contour.


As is represented in FIG. 3, the chamber 12 is closed off by a plastics cap 14, which possesses an outer contour which, in the installation position of the cap 14, corresponds to the outer contour of the inner part 1 which surrounds the chamber
12.  The cap 14 is connected to the inner part 1 by a living hinge 16 and held in the illustration position by a latching connection 17.


The chamber 13 is not yet closed off by a cap in FIG. 3.


* * * * *























				
DOCUMENT INFO
Description: This is a U.S. national stage of application No. PCT/EP2005/051266, filed on 18 Mar. 2005. Priority is claimed on the following application(s): Country: Germany, Application No.: 10 2004 018 869.6, Filed: 19 Apr. 2004.BACKGROUND OF THE INVENTIONThe invention relates to a device for detecting the movement of a movable component, the device having an inner part and the inner part possessing a housing in which conductors are disposed which bear electrical components and a sensor elementand which with their one ends protrude from the inner part to form plug contacts, the inner part being encapsulated by injection-molding or casting methods in such a way that the plug contacts project into a plug socket in the plastics housing.In devices of this type, it is known that, in the injection-molding to encapsulate the inner part with the plastics housing, the electrical components and/or the sensor element are also directly encapsulated. Both during production, as a resultof the injection pressure and the high temperatures of the injection-molding compound and the subsequent cooling thereof, and later during operation in the event of temperature fluctuations, the connections of the electrical components and/or of thesensor element are subjected to mechanical load and can become detached.In sensor elements which react to mechanical load with changes in their electrical properties, the result may be considerable losses in accuracy, or even failure of the device.Moreover, the thermal and the compressive load can lead to defects in sensitive electrical components.SUMMARY OF THE INVENTIONAn object of the invention is therefore to provide a device of the type stated in the introduction which prevents damage to the electrical components and/or to the sensor element.This object is achieved according to the invention by the fact that the electrical components and/or the sensor element are covered by covers and are encapsulated by the plastics housing by injection-molding or castin